Polyethylene (PE) pressure pipes are a popular choice for modern infrastructure projects thanks to their durability, corrosion resistance, and long service life. Continued advances in materials, technology, and installation techniques have steadily improved performance, making PE pipes suitable for an increasingly broad range of demanding applications.
One area where uptake has been limited is in very large-diameter pressure pipe systems. This is not due to pipe performance, but because of the cost and technical constraints associated with jointing at very large diameters. Addressing these jointing challenges is key to unlocking the full potential of large-diameter PE pressure pipe systems.
Established jointing methods such as butt welding and electrofusion are proven and widely used. However, at large diameters and in confined or demanding environments, their use is constrained by practical limitations, including long installation times, heavy and specialized equipment requirements, and sensitivity to pipe ovality.
snapfuse® was designed specifically to address these challenges. Developed by STAR Engineering Systems GmbH, headquartered in Wesel, Germany, snapfuse is a patented electrofusion welding technology that simplifies the process of connecting sections of large-diameter polyethylene pressure pipes.
It works by integrating the heating element directly into one pipe end, removing the need for separate electrofusion couplings or specialized equipment. The result is a pressure-class-compliant, pull-resistant joint that can be produced with a short set-up time, fewer on-site steps, smaller trenches, and less reliance on welding expertise—improving installation efficiency and reducing costs.
snapfuse enables a pressure class conform joint, welded super-fast, every time.
© STAR Engineering Systems GmbH
The technology also addresses the issue of pipe ovality, which becomes more pronounced at larger diameters. It does this through a conical self-aligning joint profile that automatically centers the pipe ends during jointing, preventing gaps.
Together, these factors expand the range of use cases for PE pipe systems, increasing their suitability at diameters of up to 3,500 mm and beyond, as well as in challenging and sensitive installation environments.
Beyond its installation and performance advantages, snapfuse can improve the sustainability of pipe installation. By eliminating additional fittings and reducing the amount of welding equipment that needs to be transported to site, it helps lower transport requirements and associated emissions. In addition, the simplified jointing process and lower equipment needs can make installation more practical in narrow trenches, helping to limit ground disturbance.
El Mehdi Tamasna, General Manager at STAR Engineering Systems GmbH, explains:
“Global customer satisfaction and our commitment to environmentally friendly technologies motivate us to develop innovative solutions for plastic piping construction. Our solutions optimize logistics costs, overcome technical challenges and enable faster, safer and more environmentally friendly work processes on pipe installation sites.”
snapfuse installation in progress – connecting large-diameter PE pipes with precision and speed.
© STAR Engineering Systems GmbH
As infrastructure demands grow, it’s vital that PE pipe systems—with all their advantages—can be deployed across as wide a range of applications as possible. By addressing long-standing jointing challenges, snapfuse helps make that possible.
Reliable system performance, however, depends not only on the jointing technology, but also on the quality and consistency of the pipes themselves. At Borealis, we offer a broad portfolio of polyethylene materials for demanding pipe and fitting applications. These materials combine mechanical strength, resistance to slow crack growth, and process stability—properties that are particularly important in large-diameter systems, where durability is critical as repair or replacement can involve significantly greater logistical effort and cost.
Together, advanced jointing technologies and high-performance materials are helping meet the demands of modern infrastructure—supporting reliable, efficient, and future-ready PE pressure pipe systems.
As Yazgan Mete, Senior Marketing Manager Infrastructure at Borealis, explains:
“By collaborating with technology leaders like STAR Engineering Systems, we’re able to offer our customers not just high-performance materials, but also cutting-edge solutions that simplify installation and improve long-term reliability. Together, we’re enabling life’s essentials.”
snapfuse advanced jointing technology unlocks new possibilities for large-diameter PE pressure pipes
© STAR Engineering Systems GmbH